|Publication number||US8201909 B2|
|Application number||US 12/629,995|
|Publication date||Jun 19, 2012|
|Filing date||Dec 3, 2009|
|Priority date||Dec 3, 2008|
|Also published as||CN102239054A, CN102239054B, EP2352651A1, EP2352651A4, US20100134549, WO2010065697A1|
|Publication number||12629995, 629995, US 8201909 B2, US 8201909B2, US-B2-8201909, US8201909 B2, US8201909B2|
|Inventors||Mike Barbour, Mark R. Thackray, Charles W. Gilson|
|Original Assignee||Videojet Technologies Inc.|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (44), Referenced by (4), Classifications (10), Legal Events (5)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This application claims the benefit of U.S. Provisional Application No. 61/119,520 filed Dec. 3, 2008, and incorporated herein by reference in its entirety.
Embodiments of the invention relate to inkjet printing systems and methods. More specifically, the invention pertains to inkjet printing systems and methods that incorporate dot-matrix fonts to form images on a print medium. In addition, embodiments of the invention also relate to thermal inkjet printing systems that utilize the dot matrix font.
Dot matrix font or formatting is a fundamental component for inkjet printing systems. Inkjet printheads include an array of orifices (also referred to as “nozzles”) on the printhead wherein each nozzle is associated with an ink ejection chamber. Ink is ejected from the nozzles and chambers in droplet form onto a print medium in response to print commands generated by a controller. In thermal inkjet printing systems resistive heaters at the ejection chambers heat the ink in the chamber causing the ink to vaporize forming rapidly expanding pressure bubbles that force the ink drops from the chamber. The piezo-type printheads use mechanically vibrating piezo-transducers to eject the ink drops from the chambers and nozzles. In either type, the printhead may be mounted on a carriage that moves the printhead back and forth on an X-axis relative to a print medium, which is moving in a Y-axis direction relative to the printhead. In other inkjet printing systems, the printhead may remain stationary relative to movement of the print medium.
Images or characters are formed on the print medium by ejecting the ink drops according to an arrangement of dots in a dot matrix consisting of rows and columns of pixels. Each pixel represents a potential ink drop or dot. The arrangement of the dots relative to one another on the dot matrix dictates which nozzles eject ink to form an image, and the timing of the ejections. The quality of an image printed depends in part on the resolution capabilities of the printing system. Resolution is measured as the number of ink drops that can be printed in one linear inch. A typical desk top inkjet printer has resolution capabilities of three hundred dots per inch (300 dpi). In order to increase resolution, the dot size (consequently nozzle size) may be decreased. In addition, the ejection frequency for a nozzle (number of times a nozzle is fired for a given time interval) may be increased to fit more dots within a determined space. This allows for optimal dot overlap to minimize white spaces and jagged edges in a printed character.
With respect to single-pass printing, for example in production line printing, two factors constrain printable dot density. The maximum vertical dot density is limited by the physical spacing of the nozzles as arranged on the printhead. In addition, the maximum horizontal dot density is limited by the maximum frequency (drops/second) at which a nozzle can eject drops divided by the relative speed of the printhead or print medium. Higher speeds mean lower horizontal drops per inch.
A typical printhead nozzle arrangement includes at least two columns (first column and second column). The nozzles in each column are horizontally offset relative to one another; and, the first and second columns are vertically offset relative to one another. Print command signals are multiplexed such that, the columns eject ink simultaneously, and ink drops generated from the second column fill in gaps or spaces in an ink dot column generated by the first nozzle column. In addition, the rate at which the printhead and/or print medium move relative to one another and the frequency at which the nozzles are capable of firing determine a horizontal dot density. These factors provide a maximum dot overlap with a relatively high resolution, if the print medium or printhead are moving at a given rate of speed. However, if the rate of speed of the printhead or print medium is increased or too high relative to the printhead/nozzle maximum ink ejection frequency, the dot overlap and resolution is compromised.
Embodiments of the invention include an inkjet printing system for optimizing print quality at print speeds that are greater than a given print speed associated with an ink drop ejection frequency for a printhead. The inkjet printing system may comprise a printhead in fluid communication with an ink source and in electrical communication with at least one controller. The printhead has at least a first column of a plurality of nozzles and a second column of a plurality of nozzles on the printhead for ejecting ink onto a print medium in droplet form. Each of the nozzles in the first column are spaced apart from one another, the nozzles in the second column are spaced apart from one another and each of the nozzles in the first column are vertically offset relative to the nozzles in the second column and do not share a horizontal axis with any of the nozzles in the second column.
At least one controller is configured to generate print control signals relative to the formation of an image on the print medium. Responsive to the print control signals ink from the first column of nozzles is ejected in alternating succession with the ejection of ink from the second column of nozzles wherein one or more images are printed on the print medium in a single pass of the print medium and the printhead relative to one another. In an embodiment, the inkjet printhead and print medium move relative to one another at an optimal print speed of x and the printhead is capable of ejecting ink in droplet form at a maximum frequency of f and the nozzles in both columns are fired simultaneously to achieve a maximum horizontal dot density in which the horizontal dot density matches a vertical dot density. In addition, the printhead is capable of firing the nozzles in alternating succession at print speeds greater than x, and up to about 2x, to optimize print quality at print speeds that may exceed the optimal print speed associated with the maximum firing frequency of the printhead, and produce an image in which the horizontal dot density matches the vertical dot density.
In embodiments described herein as a system or method, selected images are printed in a single pass of the print medium and printhead relative to one another. The image generated may include a checkerboard pattern that includes a plurality of ink dot columns printed by the first nozzle column that are spaced apart on the print medium forming gaps there between. The second nozzle columns form ink dot columns at the gaps between and the ink dot columns from the first nozzle column forming the checkerboard pattern. The printed image includes a dot matrix having a plurality of dot columns and dot rows that have equal dot densities.
A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained.
Reference will now be made in detail to the embodiments consistent with the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals are used throughout the drawings and refer to the same or like parts. While the invention is described below in reference to a thermal inkjet printer, the invention is not so limited and may be incorporated into other inkjet printing systems that utilize other technologies, such as piezo-transducers to eject ink. The term “nozzle” as used herein shall mean the orifices formed in a printhead cover plate through which ink is ejected and/or shall also include such orifices and other components of the printhead such as an ejection chamber from which the ink is ejected. In addition, the described system and method for an inkjet printing system is not limited to application with a printhead assembly mounted to a cartridge housing, which may or may not be a disposable cartridge. The present invention may be used with printheads permanently mounted in printing systems and an ink supply is provided as necessary for printing. So the term cartridge may include a permanently mounted printhead only and/or the combination of the printhead with the ink source.
In addition, the term checkerboard font as used herein describes an alphanumeric image generated on a print medium and is provided by way of example only. The invention is intended to encompass checkerboard patterns for any images that may be printed on a print medium. Also, the term “maximum dot density” is intended to mean a dot density achieved in a printing operation whereby a horizontal dot density matches a vertical dot density at a given firing frequency and print speed wherein print speed is the rate of speed at which a printhead and print medium move relative to one another.
Before describing in detail the particular system and method for inkjet printing in accordance with the present invention, it should be observed that the present invention resides primarily in a novel combination of hardware and software elements related to said method and apparatus. Accordingly, the hardware and software elements have been represented by conventional elements in the drawings, showing only those specific details that are pertinent to the present invention, so as not to obscure the disclosure with structural details that will be readily apparent to those skilled in the art having the benefit of the description herein.
With respect to
The printhead 12 comprises an array of nozzles 20 formed thereon for ejecting ink in droplet form onto a print medium 18. The printhead 12 may be an integrated chip on which a nozzle plate 22 is affixed, and the nozzles 20 may be orifices having been formed in the nozzle plate 22 using fabrication techniques know to those skilled in the art. The chip portion of the printhead 12 includes a plurality of ink ejection chambers 24 wherein each chamber 24 is associated with a nozzle 20. The chambers 24 are in fluid communication with an ink source (not shown) via an ink slot 26 and channels 28. The printing system 10 also comprises a drive mechanism to eject ink from the chambers responsive to print commands. More specifically, the printhead 12 is placed in electrical communication with the controller 14, which, on command, transmits print control signals 16 and 17 to the printhead 12 and mechanisms to move the print medium 18, respectively. In the case of a thermal inkjet printer and in response to the print control signals 16, transistors (not shown) and resistive heaters (not shown) associated with the nozzles 20 are activated to generate ink drops ejected from the nozzles 20.
Embodiments of the invention may be used on inkjet printing systems that generate an image on a print medium in a single pass of the print medium 18 relative to the printhead 12, or vice versa. Examples of such printing systems are used in production line printing systems that print bar codes, dates or other information on product packaging that is moving past a stationary printhead. Two factors that may constrain a printable dot density in such single-pass printing systems comprise: (1) the maximum vertical dot density is limited by the physical spacing of the nozzles 20 on the printhead 12; and, (2) the maximum horizontal dot density is limited by the maximum frequency at which a nozzle 20 can eject drops (drops/second) divided by the relative speed of the printhead 12 and the medium 18, which shall be referred to as print speed measured in inches/second or feet/minute.
As shown in
In an embodiment, the printhead nozzles 20 are arranged on the printhead 12 in such a manner to provide a dot matrix having a maximum dot density of 240 dpi×240 dpi at a print speed of 150 ft/min, wherein the horizontal dot density matches the vertical dot density. In a one half linear inch area centered on the printhead 12, each of the columns 30 and 32 includes sixty (60) nozzles 20. The nozzles 20 in each of the columns 30 and 32 may be vertically spaced apart from one another a distance d1 of 1/120″. The nozzles 20 in column 30 are vertically offset a distance d2, or 1/240″ relative to nozzles 20 in the second column 32 to achieve a vertical dot density of 240 dpi.
The printhead 12 and printing system 10 may generate ink drops having volumes to provide some overlap of adjacent printed dots. For example selected volumes may generate ink dots on the print medium 18 that are about 106 μm to about 150 μm in diameter, with about 125 μm to about 130 μm being a target diameter with a 12 μm overlap between adjacent drops. With these selected volumes, the maximum frequency at which any one nozzle 20 may fire is about 7.2 kHz. When nozzles 20 in both columns are fired simultaneously at a print speed of 150 ft/min, a maximum horizontal and vertical dot density of 240 dpi×240 dpi is achieved as shown in
In reference to
As shown in
With respect to
As explained above, the print speed associated with the above-described examples is 150 ft./min. So with a maximum ink ejection (firing) frequency (f) at a given print speed (x) the printing system 10 and printhead 12 are able to generate images on the print medium 18 having a maximum vertical and horizontal dot density. However, if the print speed is increased the horizontal resolution of the image may be compromised without increasing the ink ejection frequency. By increasing the print speed when the nozzles 20 in both columns 30 and 32 are firing simultaneously, the horizontal dot density matching the vertical dot density cannot be achieved. By way of example, if the print speed is doubled (2x) to 300 ft/min, and the columns 30 and 32 are ejecting ink drops simultaneously; the horizontal dot density is only one half, or 120 dpi. As shown in
On the other hand, if the columns 30 and 32 of nozzles 20 can be fired in alternating succession as the print medium 18 and printhead 12 move relative to one another, a checkerboard pattern is created as shown in
In order to alternate the ink ejection from columns 30 and 32 to create the checkerboard pattern at twice the print speed required to achieve the maximum dot density, the time (t) required to fire all the nozzles 20 on the printhead 12 in either column 30 or 32 must be less than ˝ the time between the ejection of successive drops from the same nozzle 20. Considering the above described parameters, if the amount of time to fire a nozzle is 4 μs and by way of example, if the nozzles 20 in a single column are multiplexed using eleven groups of ten to twelve nozzles 20, then the amount of time (t) to fire all the nozzles 20 in either column 30 or 32 is 44 μs (11×4 μs). If the printhead 12 or nozzles 20 have a firing frequency of 7.2 kHz, then 139 μs will have elapsed between successive firing/ejection from a single nozzle 20. That is, the time spent moving from one dot column to a next dot column for either column 30 or 32 to eject ink drops at a horizontal density of 120 dpi is 139 μs at 300 ft/min; and, the time spent moving 1/240″ is half of 139 μs or 69.5 μs. Therefore, while each column 30 and 32 of nozzles 20 is constrained to print consecutive dot columns on the print medium 18 that are spaced apart 1/120″ at 300 ft/min., one of the nozzle columns 30 or 32 can print a dot column mid-way between vertical dot columns formed by the other nozzle column 30 or 32.
With respect to
With respect to
With respect to
Patents, including U.S. Pat. Nos. 4,748,453 and 6,318,832 disclose printing systems that generate checkerboard pattern on a print medium; however, such systems are not generating an entire or complete image in a single pass of the printhead relative to the medium or vice versa. Indeed, in such systems the printhead makes multiple passes over the print medium generating a checkerboard pattern in each pass to overlap dots and cover unprinted areas on the medium. Moreover, such multi-pass processes are used for systems that demand high resolution images; therefore, multiple passes are used to eliminate jagged edges or gaps that may be acceptable for lower resolution demands. In contrast, in response to input print commands, embodiments of the present invention print a complete or final image or images having the checkerboard pattern in a single pass.
A flow chart is depicted in
For example, the controller 14 may include a database 64 that includes a dot matrix for each image input or a plurality of images input into the controller 14. In as much as the checkerboard font may be used at any print speed that is equal to or less than 2x, the controller 14 may select a checkerboard font each time a print command is initiated regardless of the print speed. More specifically, the controller 14 may generate a dot matrix that includes a maximum dot density (i.e. 240 dpi×240 dpi) for an image that may be generated at a given print speed (x); however, the controller 14 may identify/select all the pixels necessary to print a checkerboard font, which will not include all the pixels for an image with a maximum dot density. For example, pixel columns in a dot matrix may be identified or distinguished as odd and even pixel columns and the pixel data within a column may be identified as even and odd pixel data. The controller 14 may be configured to select the odd pixel data when printing the odd pixel columns and the even pixel data when printing the even pixel column. That is, the controller 14 is configured to select every other pixel data in a column for printing and in an adjacent column selects the pixel data adjacent to the pixel data not selected in the previous column. Alternatively, the controller 14 may generate a dot matrix 62 that includes only those pixels necessary to complete the checkerboard font. In either case, in step 46 one or more print control signals 16 are transmitted to the printhead 12. With respect to step 48, in response to the print control signals 16, the nozzles 20 in first and second nozzle columns 30 and 32 are fired in alternating succession to print the desired image on the print medium 18 in a single pass.
In another embodiment, and with respect to
In this manner, a user of the disclosed novel inkjet printing system 10 may choose to select the checkerboard font to optimize a print quality at scan or prints speeds that are higher than an optimal print speed for a given maximum firing frequency. At such print speeds embodiments of the invention optimize the amount of space that may be filled by ink dot columns, and avoids printing stripes that may compromise the print quality. In addition, the amount of ink may be conserved if one accepts a lower resolution image than generated when printing at the optimal speed associated with the maximum firing frequency.
Embodiments described above may be implemented on a suitable computer system, controller, data, or generally a computer readable medium. For example, the steps of the methods described above may correspond to computer instructions, logic, software code, or other computer modules disposed on the computer readable medium, e.g., floppy disc, hard drive, ASIC, remote storage, optical disc, or the like. The computer-implemented methods and/or computer code may be programmed into an electronic control unit of the printing system,
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only and not of limitation. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the teaching of the present invention. For example, while specific examples of ink drop density, firing frequencies, ink drop diameter, the disclosed and claimed invention is not so limited, but may encompass other such printing parameters that allow the printhead to eject ink drops to form dot columns in alternating succession to print an image in a single pass. Accordingly, it is intended that the invention be interpreted within the full spirit and scope of the appended claims.
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|U.S. Classification||347/14, 347/42, 347/40, 347/41|
|International Classification||B41J29/38, B41J2/155, B41J2/145, B41J2/15|
|Dec 3, 2009||AS||Assignment|
Owner name: VIDEOJET TECHNOLOGIES INC.,ILLINOIS
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BARBOUR, MIKE;THACKRAY, MARK R.;GILSON, CHARLES W.;REEL/FRAME:023598/0354
Effective date: 20091202
Owner name: VIDEOJET TECHNOLOGIES INC., ILLINOIS
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BARBOUR, MIKE;THACKRAY, MARK R.;GILSON, CHARLES W.;REEL/FRAME:023598/0354
Effective date: 20091202
|Sep 18, 2012||CC||Certificate of correction|
|Jan 29, 2016||REMI||Maintenance fee reminder mailed|
|Jun 19, 2016||LAPS||Lapse for failure to pay maintenance fees|
|Aug 9, 2016||FP||Expired due to failure to pay maintenance fee|
Effective date: 20160619